2020040004 Service Bulletin/Repair Instructions

Emissions Campai i Emissions Campaign Bulletin
Mercedes-Benz
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ign
Campaign No. 2020040004, May 2022
Campa
TO: ALL MERCEDES-BENZ and FREIGHTLINER SPRINTER CENTERS
Issions
SUBJECT: Model 906 (Sprinter)

Model Year 2015

Modification to the emissions control system
tii)
Daimler Vans USA, LLC (“DVUSA”) and Mercedes-Benz USA, LLC (“MBUSA’”) are performing an

emissions campaign on certain 906 Sprinter vehicles in order to modify to the vehicles’ emissions control

system. EPA and CARB have approved this emissions modification for these MY15 Sprinter (Model

906) vehicles. An authorized Mercedes-Benz or Freightliner Sprinter dealer will replace certain

emissions control system components and update certain software in the affected vehicles at no cost to

the owner of the vehicle.
Prior to performing this Emissions Campaign:
« Please check VMI to determine if the vehicle is involved in the emissions modification campaign and

if it has been previously repaired. Always Check VMI for any open campaigns, and perform

accordingly.
Please review the entire Emissions Campaign bulletin and follow the repair procedure exactly as

described.
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ign
Campa
Approximately 15,010 vehicles are involved.
Issions
Order No. V-RC-2020040004
tii)
THETA
This bulletin has been created and maintained in accordance with MBUSA-SLP S423QH001, Document and Data

Control, and MBUSA-SLP S424HH001, Control of Quality Records.
MA see ROSS Ue) ET: Msc eS)
8 Emissions Campaign 2020040004
Emissions Campaign 2020040004

Update May 2022
© Model: 906 Sprinter

o Model Year: 2015 4x2

o Engine: 6-Cylinder Diesel (OM 642)
Warranty Information
Damage Code l Operation No. Time Operation Text

Denial of AEM

49 10N 01 use operations for | up to2hr | Diagnosis time for pre-inspection if client declines

labor performed to reverse non-compliant modifications

Perform AEM

0797098 02 1213 2.1 hr l Perform work package for field measure

Additional: Mobile AEM at customer location

2181200 00 9627 +50% Mobile AEM Labor surcharge

sublet $75 travel allowance

Additional: Mobile AEM at customer location requiring overnight accommodation

21813 00 00 9627 +50% Mobile AEM Labor surcharge

sublet $100 travel allowance
Parts Overview
NOx sensor downstream SCR catalytic NOx sensor upstream of

of SCR catalytic converter converter SCR catalytic converter
Reference last page for complete list of parts to perform AEM
8 Emissions Campaign 2020040004
Scope of Work Outline
(i) Read and. follow all pages of work instructions completely! Page:

1. Safety Notes 4-18

2. Lifting and Ramps 19-21

3. Initial Quick Test 22-28
a. Upload print-out to paperless pXD

b. Evaluate pre-existing faults (see Pre-Inspection Guide below)
4. Pre-Inspection Special Procedure 29-32

a. Includes visual inspection of Exhaust Aftertreatment system (see Pre-Inspection Guide below)

5. Replacement of AEM parts 33-44
a. NOx Sensor Upstream of SCR Catalytic Converter

b. NOx Sensor Downstream of SCR Catalytic Converter

c. SCR Catalytic Converter

6. Execution of AEM Special Procedure 44-55

a. Includes guided steps: Software updates of CDI, ETC, IC, and SCR

b.  Fill-out and Install AEM Label

c. Result Report to verify successful completion of all AEM steps

i. Upload print-out to paperless pxD

7. Final Quick Test 56-62

a. Upload print-out to paperless pXD

b. Erase stored faults caused by the workshop

8. Parts List 63
Pre-Inspection Guide
1. Pre-existing fault codes causing a Check Engine Light (CEL):

a. If component causing fault will be replaced as part of the AEM:

i. Perform AEM - No additional action is needed

b. If component causing fault will be covered by the AEM Extended Warranty:

i. Perform AEM

ii. Perform repair of pre-existing fault

iii. Submit AEM Extended Warranty claims on a separate Repair Order after AEM claim is submitted

c. If component causing fault will not be replaced as part of AEM and not covered by AEM Extended Warranty:

Provide client with repair estimate, advise client AEM will not resolve Check Engine Light (CEL)

Document on Repair Order if client approves or declines repairs

iii. Perform AEM regardless if client approves or declines repairs

d.  Alist of AEM Extended Warranty covered components is available in: XENTRY / CDI / Special Procedures /

Exhaust Aftertreatment Service Measure / Extended Warranty

2. Non-Compliant Alterations to the Exhaust Aftertreatment system found during the visual Pre-Inspection:

a. Document all non-compliant alterations to the Exhaust Aftertreatment system on the Repair Order

b.  Ifaltered component(s) will be replaced as part of the AEM:

i. Perform AEM

c. If altered component(s) inhibit AEM installation or will sustainably affect the operation of the AEM:

i. Provide client with a repair estimate to reverse non-compliant alterations

1. If client approves repairs:

a. Reverse non-compliant alterations

b. Perform AEM

2. If client refuses repairs:

a. Do not perform AEM - Vehicle ineligible

b. Claim ‘Denial of AEM’ damage code and labor ops for diagnosis time performed

3. If technical assistance is needed, create a PTSS case
8 Emissions Campaign 2020040004
AEM installation Videos
Exemplary videos of the AEM installation are available via the following:
o XENTRY Workshop (XiW) / VAN / Emissions Modification Program

© Scan the QR code below with a mobile device and log-in with your XENTRY credentials
Campaign 2020040004 Video:
Emissions Campaign 2020040004
Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
k of injury. Skin or eye

injuries may result when

handling hot or glowing objects.
Wear protective gloves,

protective clothing and safety

glasses, if necessary.
Risk of injury
Contact with hot or glowing objects without suitable

protective clothing causes severe burns to skin and eyes.
When glowing objects come into contact with water, they

produce hot steam or cause the water to splash, which can

cause serious burns to skin or eyes.
If hot or glowing objects come into contact with unprotected

skin or eyes, they can cause serious and even permanent

injuries.
li)
There is a risk of fire when glowing objects come into

contact with combustible material.
Safety precautions/instructions
+ Wear protective clothing, safety glasses and heat-

resistant gloves.
+ Only transport hot or glowing objects with suitable aids.

+ Avoid the formation of sparks and contact with
combustible material when handling glowing objects.

First aid measures
+ Treat affected areas of skin with plenty of cold water

and cover with sterile dressings.
+ Consult a physician immediately.
Emissions Campaign 2020040004
Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from

working on the engine while it is being started or when it is running.
Risk of accident from vehicle
and burns) resulting from
being started or when it is

running.
starting off by itself when engine

running. Risk of injury (bruises
working on the engine while it is
Secure vehicle to prevent it from

starting off by itself. Wear

closed and snug-fitting work

clothes. Do not touch hot or

rotating parts.
Potential risks
Risk of accident
Caused by the vehicle starting off by itself during the

starting procedure
(e.g. during compression test) due to engaged gear or

with the engine running and vehicles with automatic

transmission due to selector lever position "P" or
“N" not being engaged (except for vehicles that do not

have selector lever position "P")

Risk of injury
Severe injuries can be caused by freely rotating parts in

the area of the running engine.
Because the engine heats up when operating, serious
burns can be caused by touching unshielded parts.
Safety instructions/precautions
+ In general, only work on a running engine when it is

absolutely necessary.
+ Apply parking brake before starting the engine.
+ The vehicle is to be secured against moving forwards or

backwards.
+ The person performing tests on a vehicle with the

engine running must sit in the driver's seat to be able to

prevent the vehicle from moving.
It is not permitted for persons to be in the danger zone

in front of or behind the vehicle while tests are being

performed.
Shift the gearshift lever to neutral on vehicles with

manual transmission.
On vehicles with automatic transmission, move selector

lever into position "P" or "N" (except for vehicles that

do not have selector lever position "P").
On vehicles that do not have selector lever position

the selector lever is to be secured against

unauthorized access.
Wear closed and snug-fitting work clothes.

Remove all jewelry such as necklaces, rings, etc.

Wear suitable head wear to cover long hair.
Before commencing any work on the running engine,

familiarize yourself with the location of potentially hot

parts.
When carrying out work when starting the engine or

when the engine is running, do not touch any hot or

rotating parts.
Use the exhaust extraction system.
First aid measures in the event of burns
+ Do not rub the skin areas affected; rinse with plenty of

cold water and cover skin with sterile dressings.
Consult a physician immediately.
Emissions Campaign 2020040004
Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.
Risk of injury. Moving parts

can pinch, crush or, in extreme

cases even sever extremities.
No parts of the body or limbs QWaming
should be within the operating

area of mechanical components

when moving components.
Risk of injury
When working on components that can be moved either by

hand, by means of electric motors, or hydraulically/

pneumatically via a connecting mechanism, serious injuries

can occur due to body parts being cut, pinched or crushed.
Safety instructions/precautions

+ Monitor hazard area.
Secure the operating area of mechanical components

against interference when parts are in motion.
Never touch the mechanism of a component while it is

being actuated by electric motors via the diagnosis or by

direct actuation (terminal 30).
Choose a test cable of sufficient length.
® Emissions Campaign 2020040004
Risk of death caused by vehicle slipping or toppling off of the lifting platform.
Risk of death caused by Align vehicle between vehicle lift
vehicle slipping or toppling off of | columns and position the four

the lifting platform support plates at the vehicle lift

support points specified by the

vehicle manufacturer.
Risk of accident and injury fi]
Ensure that the vehicle is ideally aligned and secured This list of hazards is not complete.
against tilting according to the general safety specifications — The safety specifications of the respective country are

and regulations. always valid. The user is personally responsible for
Non-observance of the safety specifications can cause the | complying with these.

vehicle to slip off the lift system and thereby result in life

threatening or fatal injuries.
Emissions Campaign 2020040004
Risk of burn injuries and scalding when working at AdBlue® lines and the components attached to them. Risk of injury

to skin and eyes when handling AdBlue®. Risk of poisoning caused by swallowing AdBlue®
Risk of burn injuries and

scalding when working at

AdBlue® lines and the

components attached to them.
when handling AdBlue®. Risk

of poisoning caused by

swallowing AdBlue®
Risk of injury to skin and eyes
Pour AdBlue® into suitable Awaming
containers only. Wait until the

pressure is released before

starting any work on the

exhaust aftertreatment system.
Potential risks
Risk of burn injuries and scalding
The AdBlue® lines and all components attached to them

are under pressure during operation and remain so after

the engine is switched off and may be hot. There is a risk of

burn injuries. There is a risk of scalding caused by

escaping hot AdBlue® when the line system is opened.
Risk of injury
There is a risk of skin irritation and eye damage on contact

with AdBlue®.
Risk of poisoning
There is a risk of poisoning if AdBlue® is swallowed.
Rules of conduct
* On vehicles with electrical delivery pump, the AdBlue®

is pumped from the line back into the AdBlue® tank

after the engine is switched off.
Safety precautions for handling removed parts and

working under the vehicle
+ Wear suitable protective gloves

+ Wear protective clothing

+ Wear safety glasses
First aid measures
Contact with skin: Wash the affected skin areas with plenty

of clean water. Change wetted clothing as quickly as

possible.
* On vehicles with a compressed air system, individual

lines are flushed with compressed air after the engine is

switched off. The engine must therefore be switched off

for at least 5 minutes before work on the exhaust

aftertreatment system may begin.
+ Open connections and plugs on the system components

slowly. Cover the connecting point with rags when

opening.
Only pour AdBlue® into marked containers specially

designated for the purpose. Do not pour AdBlue® into

drinking containers
+ Wipe up any AdBlue® spills immediately as there is a

high risk of someone slipping.
Contact with eyes: In the event of contact with eyes,

immediately rinse eyes thoroughly with plenty of clear

water; contact an eye doctor if necessary.
Ingestion: rinse mouth with clean water and drink large

quantities of water. Immediately seek medical assistance.
Firefighting measures
AdBlue® is not combustible. NH3 (ammonia) can be

released in the event of fire, causing a risk of poisoning.

Firefighting measures must therefore be suited to the

surroundings.
Emissions Campaign 2020040004

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